Fiber substrate stacking method, manufacturing method of roll of fiber substrate group, fiber substrate group, and aircraft

Abstract

The present invention aims to sufficiently impregnate each layer of a fiber substrate group composed of fiber substrates, which are used for fiber-reinforced resin molding by a resin injection method, with a resin. To successively stack a plurality of fiber substrates, each of which has arrayed fiber bundles and is a material composing a fiber-reinforced resin along with a resin, with their fiber bundles oriented in the same direction, the plurality of fiber substrates are integrated in a state where border zones between the fiber bundles adjacent to each other in an array direction are aligned with one another among the fiber substrates.

What is claimed is: 
     
       1. A fiber substrate stacking method for stacking a plurality of fiber substrates each of which has arrayed fiber bundles and is a material composing a fiber-reinforced resin along with a matrix resin, wherein the plurality of fiber substrates are integrated in a state where border zones between the fiber bundles adjacent to each other in an array direction are aligned with one another among the plurality of fiber substrates which are successively stacked with their fiber bundles oriented in a same direction, wherein a border zone of each of the fiber substrates includes a channel that is formed in a thickness direction of a stacked body comprising the stacked plurality of fiber substrates, the channel configured for passage of the matrix resin. 
     
     
       2. The fiber substrate stacking method according to  claim 1 , wherein the plurality of fiber substrates are bonded together by heating and plasticizing particles of a thermoplastic resin scattered over surfaces of the fiber bundles. 
     
     
       3. The fiber substrate stacking method according to  claim 1 , wherein the plurality of fiber substrates are bonded together by disposing a sheet, which has thermoplasticity and allows passage of the matrix resin at least in a thickness direction of the plurality of fiber substrates, between each of the plurality of fiber substrates and heating and plasticizing the sheet. 
     
     
       4. The fiber substrate stacking method according to  claim 1 , wherein the fiber bundles are arrayed at a regular pitch. 
     
     
       5. The fiber substrate stacking method according to  claim 1 , wherein:
 each of the plurality the fiber substrates has a first fiber and a second fiber that hold together the fiber bundles in an arrayed state; and 
 the first fiber extends along a length direction of the fiber bundles at the position of a border zone while the second fiber extends along the array direction of the fiber bundles. 
 
     
     
       6. The fiber substrate stacking method according to  claim 1 , wherein the arrayed fiber bundles of each of the plurality of fiber substrates are aligned in one direction, and the border zones of stacked adjacent plurality of fiber substrates are aligned in a stacking direction. 
     
     
       7. A manufacturing method of a roll of a fiber substrate group in which a plurality of fiber substrates, each of which has arrayed fiber bundles and is a material composing a fiber-reinforced resin along with a matrix resin, are successively stacked with their fiber bundles oriented in a same direction by a fiber substrate stacking method when the plurality of fiber substrates are integrated in a state where border zones between the fiber bundles adjacent to each other in an array direction are aligned with one another among the plurality of fiber substrates which are successively stacked with their fiber bundles oriented in the same direction, the manufacturing method comprising the steps of:
 obtaining a form of the plurality of fiber substrates using the fiber bundles; 
 integrating the plurality of fiber substrates in the state where the border zones between the fiber bundles adjacent to each other in the array direction are aligned with one another; and 
 rolling up the fiber substrate group including the integrated plurality of fiber substrates. 
 
     
     
       8. The manufacturing method of a roll of a fiber substrate group according to  claim 7 , wherein, in the step of integrating, the plurality of fiber substrates are stitched together with fibers, which are passed between the fiber bundles adjacent to each other in the array direction, in a state where the border zones are aligned with one another. 
     
     
       9. A fiber-reinforced resin molding method comprising the steps of:
 forming a stack of a plurality of fiber substrates including the plurality of fiber substrates of the roll of the fiber substrate group manufactured by the manufacturing method according to  claim 7 ; and 
 depressurizing an inside of a cavity, where the stack is disposed, and injecting the matrix resin into the cavity to impregnate each of the plurality of fiber substrates constituting the stack with the matrix resin. 
 
     
     
       10. . A fiber-reinforced resin molding method comprising the steps of:
 forming a stack of a plurality of fiber substrates including the plurality of fiber substrates which are stacked by a fiber substrate stacking method ; and 
 depressurizing an inside of a cavity, where the stack is disposed, and injecting a matrix resin into the cavity to impregnate each of the plurality of fiber substrates constituting the stack with the matrix resin, wherein 
 each of the plurality of fiber substrates has arrayed fiber bundles and is a material composing a fiber-reinforced resin along with the matrix resin, and 
 in the fiber substrate stacking method for stacking the plurality of fiber substrates, the plurality of fiber substrates are integrated in a state where border zones between the fiber bundles adjacent to each other in an array direction are aligned with one another among the plurality of fiber substrates which are successively stacked with their fiber bundles oriented in a same direction. 
 
     
     
       11. The fiber-reinforced resin molding method according to  claim 10 , wherein, before impregnating each of the plurality of fiber substrates, a resin diffusion medium, which presents a lower flow resistance to the matrix resin than the plurality of fiber substrates, is disposed on top of the stack. 
     
     
       12. The fiber-reinforced resin molding method according to  claim 9 , wherein, before impregnating each of the plurality of fiber substrates, a resin diffusion medium, which presents a lower flow resistance to the matrix resin than the plurality of fiber substrates, is disposed on top of the stack.